System for automatically certifying the accuracy of a manufacturing machine and associated methods

ABSTRACT

A combined manufacturing machine and certifying system are operable for performing a first operation of the machine, obtaining first data by quantifying the first operation of the machine using first measurement equipment of known accuracy, performing a second operation of the machine, obtaining second data by quantifying the second operation of the machine using second measurement equipment, determining the accuracy of the second measurement equipment by quantifying the difference between the first and second data, machining a first workpiece with the machine after determining the accuracy of the second accuracy measurement equipment, performing a third operation of the machine after machining the first workpiece, and obtaining third data by quantifying the third operation of the machine using the second accuracy measurement equipment.

FIELD OF THE INVENTION

The present invention pertains to numericallycontrolled/computer-operated manufacturing machines that manipulate oneor more tools to perform manufacturing tasks and, more particularly, tothe accuracy of such manufacturing machines.

BACKGROUND OF THE INVENTION

Numerically controlled/computer-operated manufacturing machines thatmanipulate tools to perform manufacturing tasks, such as machiningparts, are widely used. It is important for the accuracy of mechanicalmovements of manufacturing machines to be maintained in order for themachines to accurately manufacture parts. Accordingly, it is common toperiodically remove manufacturing machines from service in order tofully check their accuracy and perform any adjustments that arenecessary. The accuracy of manufacturing machines is typically checkedwith traditional metrological devices, which include laser transmittersand receivers, ball-bar testing equipment, and the like. It is commonfor a manufacturing machine to be out of service for several days inorder for its accuracy to be fully checked.

Removing manufacturing machines from service in order to check theiraccuracy detrimentally decreases the number of parts that themanufacturing machines fabricate. Accordingly, it is common formanufacturing machines to be operated for as long as possible beforebeing removed from service for accuracy checks. This candisadvantageously result in the manufacture of marginally acceptable orunacceptable parts.

It is common for parts manufactured by a manufacturing machine to beinspected after they are removed from the manufacturing machine, andthis inspection is often referred to as a post operation inspection.Post operation inspections can be disadvantageously time consumingand/or require expensive equipment. For example, post operationinspections can be facilitated through the use of hand-operatedcalipers, micrometers, coordinate measuring machines, laser devices andother conventional inspection tools.

It is common for a problem with a manufacturing machine to be initiallyidentified via post operation inspections due to the disincentive forfrequently removing a manufacturing machine from service for a fullaccuracy check. However, post operation inspections often do notidentify specific corrective actions that need to be taken for amanufacturing machine that has produced an unacceptable part. The act ofmeasuring a part is a way of identifying if there is a discrepancy, butthe data associated with the measurement of the part often is not veryuseful at identifying why the discrepancy occurred. In addition,clamping, lifting, and transporting actions that are typicallyassociated with moving manufactured parts from a manufacturing machineto an inspection station or machine, as well as differences intemperature between the manufacturing location and the inspectionlocation, can disadvantageously increase the number of variables thatcan have an impact on the post operation inspection process.

In summary, it can be disadvantageous to remove a manufacturing machinefrom service for the extended period of time that is required to performa full accuracy check for the manufacturing machine. It can also bedisadvantageous to leave a manufacturing machine in service for too longand have it fabricate marginally acceptable or unacceptable parts.Further, post operation inspection procedures can be disadvantageouslytime consuming and/or expensive, they may not provide much usefulinformation about which aspect of the manufacturing machine is notoperating accurately, and they may introduce complicating variables intoany associated analysis of the manufacturing machine.

SUMMARY OF THE INVENTION

The present invention solves the above and other problems by providing acertifying system that is capable of being associated with and operatedin conjunction with a manufacturing machine. The certifying system candecrease the number of full accuracy checks that are performed for themanufacturing machine, can identify when the manufacturing machineshould be subjected to a full accuracy check, and can provide currentinformation about the accuracy of the manufacturing machine between fullaccuracy checks, so that the manufacturing machine may be utilized toaccurately inspect parts manufactured thereby in a manner that canreduce the dependence upon post operation inspection.

More specifically, in accordance with one aspect of the presentinvention, the combined manufacturing machine and certifying systemperforms operations that carry out a method. The method includesperforming a first operation of the manufacturing machine, obtainingfirst data by quantifying the first operation of the manufacturingmachine using first measurement equipment of known accuracy, performinga second operation of the manufacturing machine, obtaining second databy quantifying the second operation of the manufacturing machine usingsecond measurement equipment (e.g., machine-dedicated measurementequipment), determining the accuracy of the second measurement equipmentby quantifying the difference between the first and second data,machining a workpiece with the manufacturing machine after determiningthe accuracy of the second accuracy measurement equipment, performing athird operation of the machine after machining the workpiece, andobtaining third data by quantifying the third operation of themanufacturing machine using the second measurement equipment.

In accordance with another aspect of the present invention, the secondand third data are compared in an effort to identify any degradation ofthe manufacturing equipment.

In accordance with another aspect, the third operation includesoperating the manufacturing machine to inspect the workpiece after theworkpiece has been machined.

In accordance with another aspect of the present invention, themanufacturing machine and certifying system are combined to provide animproved manufacturing machine that is capable of sequentially machiningworkpieces by moving tools relative to the workpieces. The improvedmanufacturing machine includes a holder that is capable of holding aworkpiece, and at least one manipulator having a clamp that is operablefor gripping the tools. The manipulator is operative for moving theclamp so that a tool gripped by the clamp can be used upon theworkpiece. The improved manufacturing machine further includes astimulus device mounted at a fixed position for remaining fixed relativeto the holder while the workpieces are machined in the sequentialfashion. The stimulus devices can be optical or mechanical. The improvedmanufacturing machine further includes a sensor assembly that is capableof being gripped by and carried by the clamp while the clamp is movedrelative to the holder. The sensor assembly is operative for generatinga signal in response to being proximate the stimulus devices or stimulusprovided therefrom. The improved manufacturing machine further includesa computer system that includes a receiver, which is operative forreceiving signals generated by the sensor assembly, and a memorycontaining a database. The computer system is operative for controllingthe operation of the manipulator. Initially, the clamp holds the sensorassembly and the manipulator moves the sensor assembly to proximate thestimulus device or a stimulus provided therefrom so that the sensorassembly generates a signal and the signal is received by the receiver.Data representative of the signal is stored in the database. Thereafter,the clamp releases the sensor assembly, retrieves the tool, and themanipulator moves the tool into contact with a workpiece that is beingheld by the holder. The computer system is also operable for generatinga signal if the data in the database exceeds a predetermined value.

The present invention is capable of reducing the amount of time that amanufacturing machine is removed from service for full accuracy checks,and is also capable of obtaining and providing information about theaccuracy of the manufacturing machine during times in which themanufacturing machine is in service but the clamp(s) of themanufacturing machine are “idle.” Numerous advantages are provided byvirtue of the present invention being capable of automatically,frequently, and conveniently verifying the accuracy of a manufacturingmachine. For example, the manufacturing machine can accurately inspect apart manufactured thereby, which can reduce the need for post operationinspection. In addition, the present invention is capable of identifyingaccuracy problems with the manufacturing machine before those problemsresult in the fabrication of unacceptable parts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic end elevation view of a numericallycontrolled/computer-operated manufacturing machine that is capable ofmanipulating tools to perform manufacturing tasks, and that is equippedwith a certifying system, in accordance with a first embodiment of thepresent invention.

FIG. 2 is a schematic, isolated, front elevation view of a bed of themanufacturing machine of FIG. 1.

FIG. 3 diagrammatically illustrates a conventional open-architecturetype of computer system of the manufacturing machine of FIG. 1 that iscapable of operating in conjunction with a conventional software moduleto control operation of the manufacturing machine in a conventionalmanner, and that is further capable of operating in conjunction with asoftware module of the present invention to carry out operations of thepresent invention, in accordance with the first embodiment of thepresent invention.

FIG. 4 schematically illustrates conventional measurement equipment ofknown accuracy that is capable of being used to determine the accuracyof the manufacturing machine of FIG. 1, in accordance with the firstembodiment of the present invention.

FIG. 5 is a schematic, isolated, perspective view of an optical sensorassembly that is capable of being removably held in a receptacle of atool rack that is illustrated in FIG. 2 and is positioned on an uprightwall of the bed of the manufacturing machine of FIG. 1, and that iscapable of being releasably gripped by a clamp of an articulating armcarried by a movable carriage of the manufacturing machine of FIG. 1, inaccordance with the first embodiment of the present invention.

FIG. 6 is a perspective partial view illustrating a ring target mountedto the upright wall of the bed of the manufacturing machine of FIG. 1,in accordance with the first embodiment of the present invention.

FIG. 7 is a partial view illustrating a cube target mounted to theupright wall of the bed of the manufacturing machine of FIG. 1, inaccordance with the first embodiment of the present invention.

FIG. 8 is a schematic, isolated, perspective view of a mechanical sensorassembly that is capable of being removably held in a receptacle of thetool rack, and that is capable of being releasably gripped by a clamp ofan articulating arm carried by a movable carriage of the manufacturingmachine of FIG. 1, in accordance with the first embodiment of thepresent invention.

FIG. 9 schematically illustrates a Benchmark Database and a PerformanceDatabase contained by a computer-readable storage medium of the computersystem of FIG. 3, in accordance with the first embodiment of the presentinvention.

FIG. 10 schematically illustrates an Axis Data Set that isrepresentative of Axis Data Sets included in the Benchmark Database andthe Performance Database illustrated in FIG. 9, in accordance with thefirst embodiment of the present invention.

FIG. 11 schematically illustrates a Ring Data Set that is representativeof Ring Data Sets included in the Benchmark Database and the PerformanceDatabase illustrated in FIG. 9, in accordance with the first embodimentof the present invention.

FIG. 12 schematically illustrates a Cube Data Set that is representativeof Cube Data Sets included in the Performance Database illustrated inFIG. 9, in accordance with the first embodiment of the presentinvention.

FIG. 13 schematically illustrates an Initial Database contained by acomputer-readable storage medium of the computer system of FIG. 4, inaccordance with the first embodiment of the present invention.

FIGS. 14A-B present a flow chart illustrating high level operationsperformed in association with items illustrated in FIGS. 1-13, inaccordance with the first embodiment of the present invention.

FIG. 15 presents a flow chart illustrating operations performed usingthe conventional measurement equipment of known accuracy illustrated inFIG. 4 in the furtherance of checking and adjusting the accuracy of themanufacturing machine of FIG. 1 while it is out of service, inaccordance with the first embodiment of the present invention.

FIG. 16 presents a flow chart illustrating operations performed toestablish and adjust the accuracy of machine-dedicated measurementequipment for the manufacturing machine of FIG. 1, in accordance withthe first embodiment of the present invention.

FIGS. 17A-B present a flow chart illustrating operations performed whilethe manufacturing machine of FIG. 1 is in service, and those operationsinclude manufacturing parts, ascertaining the accuracy of themanufacturing machine using the machine-dedicated measurement equipment,and inspecting the manufactured parts.

FIG. 18 is a partial view illustrating a cube target mounted to theupright wall of the bed of the manufacturing machine of FIG. 1, inaccordance with a second embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. Likenumbers refer to like elements throughout.

Referring to FIGS. 1 and 2, a numerically controlled/computer-operatedmanufacturing machine that includes a certifying system is generallyindicated at 20, in accordance with a first embodiment of the presentinvention.

The certifying system includes measurement equipment that is dedicatedto the manufacturing machine 20, and in accordance with the firstembodiment, operations are performed to ensure that the dedicatedmeasurement equipment accurately monitors the manufacturing machine sothat the accuracy of the manufacturing machine can be frequently checkedwithout fully removing the manufacturing machine from service and sothat the manufacturing machine can accurately inspect the products itcreates.

Some of the conventional aspects of the manufacturing machine 20 willinitially be described, followed by a description that is morespecifically directed to the certifying system of the present invention.Whereas the certifying system is described in the context of aparticular type of manufacturing machine 20, different types ofmanufacturing machines and certifying systems that are capable of beingassociated with different types of manufacturing machines are within thescope of the present invention. For example and not limitation, themanufacturing machine of the present invention can be a horizontal orvertical bed, single or multiple spindle computer-operated manufacturingmachine, or the like.

Conventional Aspects of the Manufacturing Machine

All of the conventional aspects of the manufacturing machine 20 are wellknown by or should at least be readily understandable by those ofordinary skill in the art. Accordingly, the conventional aspects of themanufacturing machine 20 are only briefly or generally described herein.Absent the certifying system, which will be discussed in greater detailbelow, the manufacturing machine of the first embodiment of the presentinvention is a conventional profiling machine that is controlled by an“open architecture-type” computer system, and an acceptable example ofsuch a profiling machine is available as model Magnum H5 1000 fromCincinnati Machine of Cincinnati, Ohio.

The manufacturing machine 20 includes a bed 22 having a base 24 and anupright wall 26 extending upward from the base. Whereas, themanufacturing machine 20 of the first embodiment is a vertical bedmachine, the invention is likewise applicable to horizontal bed machinesand other types of machines. A holding system that is operative forreleasably holding a workpiece 28 (e.g., the product produced or thematerial from which the product is formed) is mounted to the uprightwall 26. In accordance with the first embodiment of the presentinvention, the holder system includes a two-dimensional array ofelectrically activated magnets 30, only a representative few of whichare identified by their reference numeral in FIG. 2. The magnets 30 areenergized to create a magnetic field that holds the workpiece/product 28to the upright wall 26, and the magnets are de-energized to release theworkpiece/product so that the workpiece/product can be removed from theupright wall.

The manufacturing machine 20 includes a tool rack 32 that is mounted tothe bed 22 and defines multiple receptacles 34. The receptacles 34 areoperative for removably holding a wide variety of different types oftools 36, such as, but not limited to, mills, dies, bits, and the like.Only a representative few of the receptacles 34 are specificallyidentified by their reference numeral in FIG. 2. The manufacturingmachine 20 is operative for selecting and manipulating the tools 36 tomanufacture a product from the workpiece 28 that is held by the holdersystem (e.g., magnets 30), as should be understood by those of ordinaryskill in the art.

The manufacturing machine 20 includes a primary carriage 38 that iscapable of being reciprocated relative to the base 24 of the bed 22along a path that is parallel to an X Axis (see FIG. 2). The primarycarriage 38 is movable through the operation of one or more linearmotors that are schematically illustrated by primary tracks 40 thatextend parallel to the X Axis and are positioned between the primarycarriage and the base 24.

The manufacturing machine 20 includes upper and lower carriages 42, 44that are capable of being reciprocated relative to the primary carriage38 along a path that is parallel to a Y Axis (see FIGS. 1-2). The upperand lower carriages 42, 44 are movable through the operation of one ormore linear motors that are schematically illustrated by secondarytracks 46 that extend parallel to the Y Axis.

The upper and lower carriages 42, 44 respectively carry upper and lowermanipulators that are preferably in the form of upper and lowerarticulating arms 48, 50. Each articulating arm 48, 50 has a mounted endthat is mounted to the respective carriage 42, 44. The end of the upperarticulating arm 48 that is opposite from the mounted end thereof is inthe form of an upper motor-driven spindle 52. The upper motor-drivenspindle 52 includes an integral upper clamp 54. Likewise, the lowerarticulating arm 50 includes a lower motor-driven spindle 56 thatincludes an integral lower clamp 58. Each of the clamps 54, 58 isoperative for gripping, manipulating and releasing tools 36 held by thetool rack 32 in the furtherance of performing manufacturing tasks, asshould be understood by those of ordinary skill in the art.

The manufacturing machine 20 includes a computer system 60 that isoperatively connected to the bed 22 and the primary carriage 38 viacommunication paths 62, 64. A conventional software module operates inconjunction with the computer system 60 so that the computer systemprovides instructions to the manufacturing machine 20 that result in themanufacturing machine performing its manufacturing tasks. There are manydifferent conventional programming languages that are available and thatcan be readily used to create the conventional software module thatoperates in conjunction with the computer system 10 so that themanufacturing machine 20 performs its manufacturing tasks. It ispreferred for the computer system 60 and its associated conventionalsoftware module to be of the “open architecture type” so that a softwaremodule of the present invention can additionally operate on the computersystem 60 in the manner discussed in greater detail below.

An acceptable example of the computer system 60 is diagrammaticallyillustrated, in isolation, in FIG. 3. The computer system 60 includesone or more data storage devices 66, a processor 68, a computernumerical control 69, one or more input devices 70, and one or moreoutput devices 72 that are connected and are capable of operatingtogether in a conventional manner that is understood by those ofordinary skill in the art. The data storage device(s) 66 includecomputer-readable storage medium and can acceptably be in the form ofhard disks and drives therefor, floppy disks and drives therefor, CDROMs and drives therefor, digital video disks and drives therefor,memory cards, or any other type of computer-readable storage medium. Theprocessor 68 is preferably a conventional computer processor. The inputdevice(s) 70 preferably include one or more conventional components suchas, but not limited to, a keyboard, a mouse, a virtual track ball, alight pen, voice recognition equipment, or the like. The outputdevice(s) 72 preferably include one or more conventional components suchas, but not limited to, a display that presents images on a screen, anda printer, or the like. Servo drives (not shown) and servo feedbackpositioning devices (not shown) are connected to and cooperate with thecomputer numerical control 69 in a conventional manner.

The conventional software module provides a graphical user interface viathe display, and the graphical user interface includes multiple displayscreens that are presented to a user of the computer system 60 via thedisplay. The display screens display information that a user has inputor selected, and information that the conventional software moduleoutputs. A user may input information in a conventional manner via theinput device(s) 70.

The conventional software module contained by the computer system 60 isdesigned in a conventional manner to direct the operations of themanufacturing machine 20. For example, the conventional software moduleprovides instructions that result in the activating and deactivating ofthe magnets 30, the moving of the primary carriage 38 back and forthalong the primary tracks 40, and the moving of the upper and lowercarriages 42, 44 back and forth along the secondary tracks. In addition,the conventional software module provides instructions that result inthe articulating arms 48, 50 moving through their multiple degrees offreedom so that the clamps 54, 58 can carry tools and approach theworkpiece 28 from a variety of different positions and in a variety ofdifferent orientations, as should be understood by those of ordinaryskill in the art.

It is common for the accuracy of the mechanical movements of themanufacturing machine 20 to degrade over time. It is conventional forthe manufacturing machine 20 to be periodically removed from service sothat its accuracy can be checked and the manufacturing machine can beadjusted, if necessary, to ensure that it is capable of accuratelymanufacturing parts. The accuracy of the manufacturing machine 20 can bechecked with traditional metrological measurement equipment of knownaccuracy. For example, FIG. 4 schematically illustrates a conventionalsystem of measurement equipment of known accuracy (MEKA) 74 that can beused to check the accuracy of the manufacturing machine 20 in aconventional manner. A typical system of MEKA 74 includes a computersystem 76 that is not linked to the computer system 60 of themanufacturing machine 20, a laser transmitter 78, a laser receiver 80,and a ball-bar tester 82 that are respectively in communication with thecomputer system via communication paths 84, 86, 88. The system of MEKA74 and a method of using it to check the accuracy of the manufacturingmachine 20 are well known to those of ordinary skill in the art. Inaccordance with one embodiment of the present invention the system ofMEKA 74 can be characterized as not being part of the certifying systemof the present invention. In accordance with another embodiment thepresent invention includes performing operations with the system of MEKA74 to check the accuracy of the manufacturing machine 20.

It is typical for the system of MEKA 74 to be a stand-alone system thatdoes not remain with the manufacturing machine 20. It is typical for thesystem of MEKA 74 to be associated with the manufacturing machine 20solely when the manufacturing machine is removed from service for thepurpose of having a full accuracy check performed thereon.

Components of or Associated with the Certifying System

Components of the certifying system will now be described, in accordancewith the first embodiment of the present invention. The certifyingsystem operates in combination with the manufacturing machine 20 and thecertifying system can be characterized as a system of machine-dedicatedmeasurement equipment (MDME), because in contrast to the system of MEKA74, the system of MDME preferably remains with the manufacturing machine20 and is relatively frequently used in combination with themanufacturing machine.

In accordance with the first embodiment of the present invention, thecertifying system (e.g., system of MDME) includes a software module thatoperates in conjunction with the computer system 60 and theabove-discussed conventional software module to facilitate operations ofthe certifying system that are described in greater detail below. Thesoftware module of the certifying system can be directly associated withthe computer system 60 if the computer system and the conventionalsoftware module are of an “open architecture type.” Alternatively, ifthey are not of the “open architecture type,” the software module of thecertifying system may be directly associated with a supplementalcomputer system (not shown) that is interfaced with the computer system60 and operates in conjunction with the computer system 60 to facilitatethe operations of the certifying system that are described in greaterdetail below. For the sake of explanation this disclosure makesreference to separate software modules, namely the conventional softwaremodule and the software module of the certifying system. Thisdistinction is made for purposes of clarification and not for purposesof limitation, as it is within the scope of the present invention forall operations, other than those that would clearly be performed by ahuman, to be controlled via instructions originating from a singlesoftware module.

Referring to FIG. 2, the certifying system (e.g., system of MDME) forthe large bed manufacturing machine 20 of the first embodiment includesa pair of optical transmitters (e.g., stimulus devices) that arepreferably X and Y laser transmitters 90, 92. A small bed machine may beconfigured with only one optical transmitter system for signalstimulation. The certifying system of the first embodiment also includesa pair of optical reflectors that are preferably X and Y laserreflectors 94, 96. The X laser transmitter 90 is operable fortransmitting a pair of closely adjacent X laser beams 98 (e.g., opticalstimulus in the form of beams of coherent light) that are parallel toone another and are diagrammatically illustrated by a single broken linein FIG. 2. It is also within the scope of the present invention for theX laser transmitter 90 to transmit a single X laser beam, so referenceherein to the X laser beam 98 should be understood to alternatively meaneither a single X laser beam or multiple parallel X laser beams, unlessit is expressly indicated otherwise or it would be understood to beotherwise by those of ordinary skill in the art. Likewise, the Y lasertransmitter 92 is operable for transmitting a pair of closely adjacent Ylaser beams 100 (e.g., optical stimulus in the form of beams of coherentlight) that are parallel to one another and are diagrammaticallyillustrated by a single broken line in FIG. 2. It is also within thescope of the present invention for the Y laser transmitter 92 totransmit a single Y laser beam, so reference herein to the Y laser beam100 should be understood to alternatively mean either a single Y laserbeam or multiple parallel Y laser beams, unless it is expresslyindicated otherwise or it would be understood to be otherwise by thoseof ordinary skill in the art.

Each of the X and Y laser transmitters 90, 92 are preferably permanentlymounted in fixed relation to the bed 22 of the manufacturing machine 20so that the paths of the laser beams 98, 100 are fixed relative to thebed and the components mounted thereto, such as the magnets 30. The Xlaser transmitter 90 is mounted so that the X laser beam 98 initiallyextends parallel to the X Axis, and thereafter the X laser beam isreflected by the X laser reflector 94 and extends parallel to the ZAxis. Likewise, the Y laser transmitter 92 is mounted so that the Ylaser beam 100 initially extends parallel to the Y Axis, and thereafterthe Y laser beam is reflected by the Y laser reflector 94 and extendsparallel to the Z Axis. Each of the X and Y laser transmitterspreferably receive instructions from the computer system 60 viacommunication paths. Those communication paths are acceptably in theform of cables, or the like, a portion of which are not shown and aportion of which are incorporated into the communication path 64 bywhich the bed 22 communicates with the computer system 60.

Each of the X and Y laser transmitters 90, 92 can be equipped with aprotective stainless steel cover (not shown). In accordance with oneexample, each of the protective covers is automatically opened when itstransmitter is to be used, and closed when its transmitter is not beingused. The opening and closing can be facilitated by conventionaloperating mechanisms, such as solenoids, pneumatic operators, hydraulicoperators, or the like. An alternative protective cover embodies apositive pressure purge system with a fixed aperture for laserprojection.

Referring to FIGS. 2 and 5, the certifying system includes an opticalsensor assembly 102 that is releasably held by a receptacle 34 of thetool rack 32. The optical sensor assembly 102 is used to check thestraight axes of the manufacturing machine 20 by being moved along andsensing the laser beams 98, 100, as will be discussed in greater detailbelow. Referring to FIG. 5, the optical sensor assembly 102 includes anoptical receiver 104 that is mounted to an adapter 106 that carries aradio frequency transmitter 108. The optical sensor assembly 102preferably further includes one or more electrical batteries (not shown)that provide power to the powered components of the optical sensorassembly.

The adapter 106 is designed to be capable of being releasably gripped byeither of the clamps 54, 58 of the articulating arms 48, 50. The opticalsensor assembly 102 preferably also includes a switch (not shown), suchas a suitably oriented mercury switch or the like, that is carried bythe adapter 106. The switch turns on the optical sensor assembly 102after it has been picked up by one of the clamps 54, 58 and moved to apredetermined orientation. The switch turns off the optical sensorassembly 102 when it is moved to a predetermined orientation (e.g., whenit is replaced in the tool rack).

The optical receiver 104 is preferably a laser receiver that is used forsensing the X and Y laser beams 98, 100. The optical receiver 104includes an array of sensors 110 that are each operative to provide anelectrical signal in response to having light, such as laser beams 98,100, incident thereon. For example, the sensors 110 can be photodiodes,charge-coupled devices, or the like. Only a representative few of thesensors 110 are identified by their reference numeral in FIG. 5. Each ofthe sensors 110 is connected by wires (not shown) to the transmitter 108and the transmitter 108 transmits signals representative of theincidence of the laser beams 98, 100 upon each of the sensors 110. Anacceptable transmitter 108 is an eight-channel digital transmitter, orthe like, which can have wireless remote control capabilities, ifdesired. In accordance with the first embodiment of the presentinvention, one of the input devices 70 (FIG. 3) of the computer system60 is a radio frequency receiver that is receptive to the signalstransmitted by the transmitter 108. More specifically regarding the Xand Y laser transmitters 90, 92 and the laser receiver 104, acceptableexamples of those items are available as Model 5D and Model 6D lasersystems from Automated Precision, Inc. located in Gaithersburg, Md.

Referring to FIGS. 2 and 6, the certifying system (e.g., system of MDME)is illustrated as including upper and lower ring targets 112, 114 (e.g.,stimulus devices) that are mounted to the upright wall 26 of the bed 22.The certifying system may include more or less than the two ring targets112, 114, and the ring targets may be located differently than isillustrated in FIG. 2. For example, in one embodiment it is preferredfor the manufacturing machine 20 to be equipped with three ring targets.In accordance with the first embodiment of the present invention, eachof the ring targets 112, 114 is preferably approximately eight inches indiameter and is placed at a convenient location on the bed 112 that isoutside of the main work envelope of the manufacturing machine 20.

The upper ring target 112 illustrated in FIG. 6 is representative of thelower ring target 114. Referring to FIG. 6, and referring to FIG. 2regarding the orientation of the X and Y Axes, the upper ring target 112includes an annular peripheral edge 116 (e.g., mechanical stimulus) thatextends in a plane that is parallel to both the X and Y Axes. Likewise,the lower ring target 114 includes an annular peripheral edge 117 (e.g.,mechanical stimulus) that extends in a plane that is parallel to boththe X and Y Axes. Each of the ring targets 112, 114 can alternatively bein the form of disks that respectively define the annular peripheraledges 116, 117.

As best understood with reference to FIGS. 2 and 7, the certifyingsystem (e.g., system of MDME) is illustrated as including a cube target118 (e.g., stimulus device) that is mounted to the upright wall 26 ofthe bed 22. The certifying system may include more than one cube target118, and the cube targets may be located differently than illustrated inFIG. 2. As best understood with reference to FIG. 7, and referring toFIGS. 1-2 regarding the orientation of the X, Y, and Z Axes that areperpendicular to one another and define a three-dimensional coordinatesystem, the cube target 118 includes multiple surfaces (e.g., mechanicalstimuli). More specifically, the cube target 118 includes an X-Y surface120 extending in a plane that is parallel to both the X and Y Axes.Likewise, the cube target 118 includes upper and lower X-Z surfaces 122,124, each of which extends in a plane that is parallel to the X and theZ Axes. Likewise, the cube target 118 includes right and left Y-Zsurfaces 126, 128, each of which extends in a plane that is parallel toboth the Y and the Z Axes.

Each of the ring and cube targets 112, 114, 118 is preferablypermanently mounted in fixed relation to the bed 22 of the manufacturingmachine 20. In addition, each of the ring and cube targets 112, 114, 118can be individually equipped with a protective stainless steel cover(not shown). In accordance with one example, each of the protectivecovers is automatically opened when its respective target 112, 114, 118is to be used, and closed when its target is not being used. The openingand closing can be facilitated by conventional operating mechanisms,such as solenoids, pneumatic operators, hydraulic operators, or thelike.

Referring to FIGS. 2 and 8, the certifying system (e.g., system of MDME)includes a mechanical sensor assembly 130 that is releasably held by areceptacle 34 of the tool rack 32. The mechanical sensor assembly 130 isused to check the rotational axes of the manufacturing machine 20, forexample by engaging the ring and cube targets 112,114,118, as will bediscussed in greater detail below. Data taken for the ring and cubetargets 112, 114, 118 is indicative of how accurately the manufacturingmachine 20 is moving in four, five, or six axis moves. This is animportant aspect for any manufacturing machine performing swarfing orcontouring cuts. The mechanical sensor assembly 130 is also used toinspect parts after they are machined from workpieces 28, as will bediscussed in greater detail below.

Referring to FIG. 8, the mechanical sensor assembly 130 includes a touchprobe 132 that is mounted to an adapter 134 that carries a radiofrequency transmitter 136. The mechanical sensor assembly 130 preferablyfurther includes one or more electrical batteries (not shown) thatprovide power to the powered components of the mechanical sensorassembly.

The adapter 134 is designed to be capable of being gripped by either ofthe clamps 54, 58 of the articulating arms 48, 50. The mechanical sensorassembly 130 preferably also includes a switch (not shown), such as asuitably oriented mercury switch or the like, that is carried by theadapter 134. The switch turns on the mechanical sensor assembly 130after it has been picked by one of the clamps 54, 58 and moved to apredetermined orientation. The switch turns off the mechanical sensorassembly 130 when it is moved to a predetermined orientation (e.g., whenit is replaced in the tool rack).

The touch probe 132 can be characterized as a sensing device that isused for sensing the ring and cube targets 112, 114, 118 and productsmanufactured from the workpieces 28 by the manufacturing machine 20. Asone specific example, the touch probe 132 is used in accordance with thefirst embodiment of the present invention to perform tests that emulatesample ball-bar planar data (as noted in ASME 5.54 standard). The touchprobe 132 includes an array of sensors 138, each of which is operativeto provide an electrical signal in response to mechanical stress. Inaccordance with the first embodiment, the subject mechanical stressresults from movement of an armature 137 that is caused by engagementbetween any one of several styli 139 and any one of the targets 112,114, 118, or the like. Acceptable sensors include displacementtransducers, such as linear variable differential transformers, straingauges, piezoelectric crystals, or the like. Only a representative fewof the sensors 130 are illustrated in FIG. 8. Each of the sensors isconnected by wires (not shown) to the transmitter 136 and thetransmitter 136 transmits signals representative of the stressexperienced by each sensor 138. An acceptable transmitter 136 is aneight-channel digital transmitter, or the like, which can have wirelessremote control capabilities, if desired. In accordance with the firstembodiment of the present invention, one of the input devices 70 (FIG.3) of the computer system 60 is a radio frequency receiver that isreceptive to signals transmitted by the transmitter 136.

In accordance with the first embodiment, the touch probe 132 is similarto an API Scanning Touch Probe available from Automated Precision Inc.of Gaithersburg, Md. The touch probe 132 is a three-dimensional scanningtouch probe capable of taking data at up to 1000 data points per second.The sensors 138 are capable of reading off-set of the styli 139 from aknown origin in three dimensions. The touch probe 132 can also emulate atouch-trigger probe for individual data point sampling.

The touch probe 132 is used, for example, to collect data from the ringtargets 112,114. More specifically, the manufacturing machine 20 isprogrammed to cause the touch probe 132 to follow each planar circle onthe ring targets 112, 114 so that the touch probe follows the machinedface of the targets and measures the deflection from the programmedpath. The touch probe 132 is used to collect ball-bar type data withoutremoving the manufacturing machine 20 from service and without mountinga traditional ball-bar device to the manufacturing machine, as will bediscussed in greater detail below.

As mentioned above, the certifying system (e.g., system of MDME)includes software module(s) that are operative in conjunction with thecomputer system 60 to facilitate operations of the certifying system, aswill be discussed in greater detail below. Those software module(s)include or provide instructions that define databases that can becharacterized as components of the certifying system. More specifically,and referring to FIG. 9, the certifying system includes a BenchmarkDatabase 140 and a Performance Database 142 that are located in one ormore of the data storage devices 66, or the like, operatively associatedwith the computer system 60. As will be discussed in greater detailbelow, the Benchmark Database 140 provides a basis against whichinformation in the Performance Database 142 can be compared for thepurpose of determining if the performance of the manufacturing machine20 has degraded or is likely to degrade over time.

As illustrated in FIG. 9, the Benchmark Database 140 includes an AxisData Set and a Ring Data Set. Similarly, the Performance Database 142includes First through Nth Axis Data Sets, First through Nth Ring DataSets, and First through Nth Cube Data Sets. Examples of representativeAxis, Ring, and Cube Data Sets 144, 146, 148 are respectivelyillustrated in FIGS. 10-12. The data sets illustrated in FIGS. 10-12 areexemplary in nature, and those of ordinary skill in the art willappreciate that it may be useful to obtain data in addition to, and datathat is different from, that indicated in FIGS. 10-12. For example, foreach of the X, Y, and Z Axes, also of interest may be angularity data,as will be discussed in greater detail below. In addition, it may bedesirable for data to be collected for additional straight axes,additional ring targets, and additional cube targets, and theseadditions could be reflected in the data sets illustrated in FIGS.10-12. The databases 140, 142 and data sets 144, 146, 148, andoperations associated therewith, are further described below withreference to the operations of the certifying system. In addition, thoseof ordinary skill in the art will appreciate that data from the AxisData Set 144 can be used to ascertain the squareness andperpendicularity of the manufacturing machine 20, and that data from theRing Data Set can be used to analyze the interactions between all of theaxes of the manufacturing machine.

Referring to FIG. 13, in accordance with the first embodiment of thepresent invention, one or more software modules of the system of MEKA 74are set up so that the system of MEKA includes an Initial Database 150located in one or more computer-readable storage mediums 152 operativelyassociated with the computer system 76 of the system of MEKA. Inaccordance with the first embodiment, the Initial Database 150 includesan Axis Data Set and a Ring Data Set, and the Axis and Ring Data Sets144, 146 illustrated in FIGS. 10-11 are representative of the data setsof the Initial Database.

Operations Associated with the Certifying System

Generally described, the certifying system of the first embodiment ofthe present invention is at least operative for determining howaccurately the manufacturing machine 20 is operating. Using data that iscollected, for example as described below, accuracy determinations arecalculated via software using methods of analysis that are based uponASME 5.54 machine tool evaluation standards. In accordance with thefirst embodiment, data is preferably taken and analyzed to evaluate thefollowing operational parameters of the manufacturing machine 20:velocity of movement; linear displacement accuracy; periodic errors;bi-directional repeatability; repeatability; straightness; angularerrors of pitch, yaw and roll; linear axis squareness; contouringperformance of X-Y, X-Z and Y-Z planes; and servo balance andadjustment. Preferably all measurements are maintained within plus orminus ten percent of benchmark data established when the manufacturingmachine 20 is prepared for release to production.

FIGS. 14A-B present a flow chart illustrating exemplary high leveloperations performed in association with the certifying system (e.g.,system of MDME), in accordance with the first embodiment of the presentinvention. At step 300 the manufacturing machine 20 is removed fromservice, meaning that the manufacturing machine is no longer operated tomanufacture products from workpieces 28. At step 303 components of thesystem of MEKA 74 that are used in the furtherance of steps 305, 310,315, 320, 325, and 330 are at least initially associated with themanufacturing machine 20, as will become apparent from the following.

Operations performed at steps 305, 310, 315, 320, 325, and 330 ensurethat subsequent thereto the manufacturing machine 20 is operative toaccurately move the upper and lower clamps 54, 58 along straight paths.The operations performed at steps 305, 310, 315, 320, 325, and 330 eachinclude operations illustrated by and described with reference to FIG.15.

At steps 305, 310, and 315 operations that are illustrated by anddescribed with reference to FIG. 15 are performed to ensure that themanufacturing machine 20 is operative to accurately move the upper clamp54 along straight paths that are respectively parallel to the X, Y, andZ Axes. These operations involve the system of MEKA 74. Morespecifically, and as will best be understood with reference to theoperations illustrated by and described with reference to FIG. 15, atsteps 305, 310, and 315 the designated component of the system of MEKA74 that is gripped by the upper clamp 54 is the laser receiver 80. Atsteps 305, 310, and 315 the laser receiver 80 is used in combinationwith the laser transmitter 78 of the system of MEKA to ensure accuratemovement of the upper clamp 54 along straight paths that arerespectively parallel to the X, Y, and Z Axes.

At steps 320, 325, and 330 operations that are illustrated by anddescribed with reference to FIG. 15 are performed to ensure that themanufacturing machine 20 is operative to accurately move the lower clamp58 along straight paths that are respectively parallel to the X, Y, andZ Axes. These operations involve the system of MEKA 74. Morespecifically, and as will best be understood with reference to theoperations illustrated by and described with reference to FIG. 15, atsteps 320, 325, and 330 the designated component of the system of MEKA74 that is gripped by the lower clamp 58 is the laser receiver 80. Atsteps 320, 325, and 330 the laser receiver 80 is used in combinationwith the laser transmitter 78 of the system of MEKA to ensure accuratemovement of the lower clamp 58 along straight paths that arerespectively parallel to the X, Y, and Z Axes.

At step 333 components of the system of MEKA 74 that were associatedwith the manufacturing machine in the furtherance of steps 303, 305,310, 315, 320, 325, and 330 are at least partially disassociated withthe manufacturing machine.

Operations performed at steps 335, 340, 345, 350, 355, and 360 areperformed to ensure that thereafter the system of MDME is capable ofaccurately monitoring movements of the upper and lower clamps 54, 58along straight paths that are respectively parallel to the X, Y and ZAxes. The operations performed at steps 335, 340, 345, 350, 355, and 360each include the operations illustrated by and described with referenceto FIG. 16.

At step 335 operations that are described below with reference to FIG.16 are performed to ensure that subsequent thereto the system of MDME iscapable of accurately monitoring movement of the upper clamp 54 along astraight path parallel to the X Axis. The straight path utilized at step335 is preferably at least proximate and parallel to, and mostpreferably coaxial with, the straight path used at step 305. Morespecifically, and as will best be understood with reference to theoperations described below with reference to FIG. 16, at step 335 thedesignated component of the system of MDME that is gripped by upperclamp 54 is the optical sensor assembly 102, and the path along whichthe optical sensor assembly is moved is at least a portion of the pathdefined by the X laser beam 98 between the X laser transmitter 90 andthe X laser reflector 94.

At step 340 operations that are described below with reference to FIG.16 are performed to ensure that subsequent thereto the system of MDME iscapable of accurately monitoring movement of the upper clamp 54 along astraight path parallel to the Y Axis. The straight path utilized at step340 is preferably at least proximate and parallel to, and mostpreferably coaxial with, the straight path used at step 310. Morespecifically, and as will best be understood with reference to theoperations described below with reference to FIG. 16, at step 340 thedesignated component of the system of MDME that is gripped by upperclamp 54 is the optical sensor assembly 102, and the path along whichthe optical sensor assembly is moved is at least a portion of the pathdefined by the Y laser beam 100 between the Y laser transmitter 92 andthe Y laser reflector 96.

At step 345 operations that are described below with reference to FIG.16 are performed to ensure that subsequent thereto the system of MDME iscapable of accurately monitoring movement of the upper clamp 54 along astraight path parallel to the Z Axis. The straight path utilized at step345 is preferably at least proximate and parallel to, and mostpreferably coaxial with, the straight path used at step 315. Morespecifically, and as will best be understood with reference to theoperations described below with reference to FIG. 16, at step 345 thedesignated component of the system of MDME that is gripped by upperclamp 54 is the optical sensor assembly 102, and the path along whichthe optical sensor assembly is moved is at least a portion of the pathdefined by the X laser beam 100 that has been reflected by the X laserreflector 94.

At step 350 operations that are described below with reference to FIG.16 are performed to ensure that subsequent thereto the system of MDME iscapable of accurately monitoring movement of the lower clamp 58 along astraight path parallel to the X Axis. The straight path utilized at step350 is preferably at least proximate and parallel to, and mostpreferably coaxial with, the straight path used at step 320. Morespecifically, and as will best be understood with reference to theoperations described below with reference to FIG. 16, at step 350 thedesignated component of the system of MDME that is gripped by the lowerclamp 58 is the optical sensor assembly 102, and the path along whichthe optical sensor assembly is moved is at least a portion of the pathdefined by the X laser beam 100 between the X laser transmitter 92 andthe X laser reflector 96.

At step 355 operations that are described below with reference to FIG.16 are performed to ensure that subsequent thereto the system of MDME iscapable of accurately monitoring movement of the lower clamp 58 along astraight path parallel to the Y Axis. The straight path utilized at step355 is preferably at least proximate and parallel to, and mostpreferably coaxial with, the straight path used at step 325. Morespecifically, and as will best be understood with reference to theoperations described below in regards to FIG. 16, at step 355 thedesignated component of the system of MDME that is gripped by lowerclamp 58 is the optical sensor assembly 102, and the path along whichthe optical sensor assembly is moved is at least a portion of the pathdefined by the Y laser beam 100 between the Y laser transmitter 92 andthe Y laser reflector 96.

At step 360 operations that are described below with reference to FIG.16 are performed to ensure that subsequent thereto the system of MDME iscapable of accurately monitoring movement of the lower clamp 58 along astraight path parallel to the Z Axis. The straight path utilized at step360 is preferably at least proximate and parallel to, and mostpreferably coaxial with, the straight path used at step 330. Morespecifically, and as will best be understood with reference to theoperations described below with reference to FIG. 16, at step 360 thedesignated component of the system of MDME that is gripped by the lowerclamp 58 is the optical sensor assembly 102, and the path along whichthe optical sensor assembly is moved is at least a portion of the pathdefined by the Y laser beam 100 that has been reflected by the Y laserreflector 96.

At step 363 components of the system of MEKA 74 that are used in thefurtherance of steps 365 and 370 are at least initially associated withthe manufacturing machine 20.

At steps 365 and 370 operations that are described with reference toFIG. 15 are performed to ensure that subsequent thereto themanufacturing machine 20 is operative to accurately move the upper andlower clamps 54, 58 respectively around proximate the upper and lowerannular peripheral edges 116, 117 (e.g., along curved paths). Theseoperations involve the system of MEKA 74. More specifically, and as willbest be understood with reference to the operations illustrated by anddescribed in regards to FIG. 15, at steps 365 and 370 the designatedcomponent of the system of MEKA 74 that is respectively gripped by theupper and lower clamps 54, 58 is an appropriate portion of the ball-bartester 82 of the system of MEKA. The ball-bar tester is used to testmovement of the upper and lower clamps 54, 58 respectively aroundproximate the upper and lower annular peripheral edges 116, 117, asshould be understood by those of ordinary skill in the art. Otherball-bar tests are preferably performed by conventional methods atvarious points on the manufacturing machine 20 in an effort to makecertain that no locational variables are present that will detrimentallyaffect the accuracy of the manufacturing machine.

At step 373 components of the system MEKA 74 that were associated withthe manufacturing machine 20 in the furtherance of steps 363, 365, and370 are at least partially disassociated with the manufacturing machine20.

At steps 375 and 380 operations that are described below with referenceto FIG. 16 are performed to ensure that subsequent thereto the system ofMDME is capable of accurately monitoring movement of the upper and lowerclamps 54, 58 respectively around proximate the upper and lower annularperipheral edges 116, 117. More specifically, and as will best beunderstood with reference to the operations described below withreference to FIG. 16, at steps 375 and 380 the designated component ofthe system of MDME that is gripped by the clamps 54, 58 is themechanical sensor assembly 130. At steps 375 and 380 the touch probe 132of the mechanical sensor assembly 130 is respectively engaged to andmoved around the upper and lower annular peripheral edges 116, 117, asis discussed in greater detail below.

The movements performed and data collected in the furtherance of theoperations of steps 335, 340, 345, 350, 355, 360, 375, and 380 simulatethe movements performed and data collected in the furtherance of theoperations of steps 305, 310, 315, 320, 325, 330, 365, and 370,respectively. That is, and for example, the movement of the upper clamp54 during step 335 simulates the movement of the upper clamp during step305, and the data collected regarding movement of the upper clamp duringstep 335 simulates the data collected regarding movement of the upperclamp during step 305.

In accordance with the first embodiment, steps 300-380 are performedimmediately after each of the following events and prior to releasingthe manufacturing machine 20 for production: installation of a newmanufacturing machine after purchase, installation of an existingmachine after relocation, after any program excursion resulting in acrash of any clamp or tool with the machine bed or production part thatrenders the machine unable to operate within the predeterminedparameters of the present invention, and after physical replacement ofhardware or software resulting in the machine being unable to operatewithin the predetermined parameters of the present invention.

At step 385 the manufacturing machine 20 is returned to service or is atleast prepared for being returned to service. At step 390 themanufacturing machine 20 is operated for manufacturing purposes byperforming the operations that are illustrated by and described withreference to FIGS. 17A-B, and some of those operations involve thesystem of MDME, as is discussed in greater detail below.

The operations illustrated by FIG. 15 will now be described, inaccordance with the first embodiment of the present invention. Asindicated above, the operations that are illustrated by and describedwith reference to FIG. 15 are performed for each of steps 305, 310, 315,320, 325, 330, 365, and 370 (FIG. 14). For each pass through theoperations described with reference to FIG. 15, the clamp, thedesignated component of the system of MEKA 74, and the path along whichthe clamp moves the designated component of the system of MEKA are asspecified by the respective one of the steps 305, 310, 315, 320, 325,330, 365, and 370 on whose behalf the operations of FIG. 15 arecurrently being performed.

At step 410, the clamp grips and picks up the designated component ofthe system of MEKA 74. At step 415 the manufacturing machine 20 isoperated so that the clamp moves the designated component along thedesignated path. At step 415 the system of MEKA 74 also obtains dataregarding the movement of the designated component that is occurring atthe current performance of step 415. At step 415 the system of MEKA 74also functions so that the respective portion of the Initial Database150 is populated with the data obtained at the current performance ofstep 415. At step 420 a determination is made as to whether the datacollected at the most recent occurrence of step 415 is indicative ofthat movement being sufficiently accurate, such as by being withinspecifications supplied by the manufacturer of the manufacturing machine20. If a negative determination is made at step 420, the manufacturingmachine 20 is adjusted in a manner that should be understood by those ofordinary skill in the art in an effort to improve the accuracy of themanufacturing machine. If a positive determination is made at step 420,control is transferred to step 430 where the clamp releases thedesignated component of the system of MEKA 74.

More specifically, at steps 410 and 430 the clamp optionallyrespectively picks up and releases the designated component of thesystem of MEKA 74 because when subsequent ones of steps 305, 310, 315,320, 325, 330, 365, or 370 (FIG. 14) utilize the same designatedcomponent of the system of MEKA it is preferred that appropriate ones ofsteps 410 and 430 be omitted to avoid having to pick up a designatedcomponent immediately after releasing the same designated component.Throughout this disclosure, when reference is made to either one of theclamps 54, 58 picking up an item, it is preferred for the item to begripped and picked up from the tool rack 32 through the movement of andactions of the clamp. Likewise, throughout this disclosure, whenreference is made to either one of the clamps 54, 58 releasing an item,it is preferred for the item to be returned to the tool rack 32 throughthe movement of and actions of the clamp.

The operations illustrated by FIG. 16 will now be described, inaccordance with the first embodiment of the present invention. Asindicated above the operations that are illustrated by and describedwith reference to FIG. 16 are performed for each of steps 335, 340, 345,350, 355, 360, 375, and 380 (FIG. 14). For each pass through theoperations described with reference to FIG. 16, the clamp, thedesignated component of the system of MDME 74, and the path along whichthe clamp moves the designated component of the system MDME are asspecified by the respective one of the steps 335, 340, 345, 350, 355,360, 375, and 380 on whose behalf the operations of FIG. 16 arecurrently being performed.

At step 510, the clamp grips and picks up the designated component ofthe system of MDME 74. At step 515 the manufacturing machine 20 isoperated so that the clamp moves the designated component along thedesignated path. In addition, at step 515 the system of MDME 74 obtainsdata regarding the movement occurring at the current performance of step515.

When step 515 is carried out in the furtherance of steps 335, 340, 345,350, 355, and 360, the designated component is the optical sensorassembly 102 and the optical receiver 104 is used to sense either the Xor Y laser beam 98, 100, depending upon the designated path. For each ofsteps 335, 340, 345, 350, 355, and 360, the designated path is definedso as to include a series of serially arranged points, and those pointsare represented in the Axis Data Set 144, where it is illustrated thateach series includes First through Nth Points. For example, a minimum ofthirty points and a maximum of fifty points are preferably selectedalong each path over thirty-six inches long, and paths under thirty-sixinches long preferably have a minimum of ten points and a maximum ofthirty points. The points are preferably equally spaced along the paths.

In accordance with the first embodiment of the present invention, datafor at least two parameters is obtained for each point. The firstparameter pertains to the position coordinates of the optical sensorassembly 102. Data for this parameter is derived based upon adetermination of which of the sensors 110 senses the respective laserbeam. The second parameter pertains to the velocity of the opticalsensor assembly 102. Data for this second parameter is derived basedupon the amount of time it takes pulses of the respective laser beam 98or 100 to reach the optical receiver 104. In accordance with anotherembodiment, data for a third parameter is obtained for each point. Datafor this third parameter is indicative of the angular orientation of theoptical sensor assembly 102. Data for the third parameter is derivedbased upon the difference in the amount of time it takes for the twoparallel X laser beams 98 to reach the optical receiver 104, or thedifference in the amount of time it takes for the two parallel Y laserbeams 100 to reach the receiver.

When step 515 is carried out in the furtherance of steps 375 and 380,the designated component is the mechanical sensor assembly 130 and thetouch probe 132 is preferably engaged to and senses the entirety of theupper and lower annular peripheral edges 116, 117 to emulate ball-bartesting. In accordance with the first embodiment of the presentinvention, for each of steps 375 and 380, the designated path is definedso as to include a series of serially arranged points, and those pointsare represented in the Ring Data Set 146, where it is illustrated thateach series of points includes First through Nth Points. The points arepreferably equally spaced along the paths. In accordance with the firstembodiment of the present invention, data for at least one parameter isobtained for each point. As illustrated in FIG. 11, the parameterpertains to the positional coordinates of the sensor assembly 130.

Whereas the operations of step 515 that are carried out in thefurtherance of steps 375 and 380 have been described above in thecontext of obtaining data at specific points, in one embodiment of thepresent invention all data obtained with respect to the peripheral edges116, 117 is obtained using circular interpolation techniques, and thosecircular interpolation techniques should be understood by those ofordinary skill in the art. In accordance with one example, when step 515is carried out for each of steps 375 and 360, it is preferred for thetouch probe 132 to be moved so as to trace the respective annularperipheral edge 116, 117 three times in clockwise and counterclockwisedirections, and for the data obtained to be averaged.

At step 520 calculations are performed to determine the accuracy of thesystem of MDME based at least upon the data obtained at the most recentoccurrence of step 515 and the corresponding data most recently obtainedat step 415 for the corresponding movement. For example, when theoperations of FIG. 16 are performed in the furtherance of step 335, theaccuracy determination made at step 520 is based upon the informationobtained at the most recent occurrence of step 515 and the informationobtained at the most recent occurrence of step 415 that occurred duringthe most recent occurrence of step 305. Likewise, when the operations ofFIG. 16 are performed in the furtherance of step 340, the accuracydetermination made at step 520 is based upon the information obtained atthe most recent occurrence of step 515 and the information obtained atthe most recent occurrence of step 415 that occurred during the mostrecent occurrence of step 310. Likewise, when the operations of FIG. 16are performed in the furtherance of step 34 5, the accuracydetermination made at step 52 0 is based upon the information obtainedat the most recent occurrence of step 515 and the information obtainedat the most recent occurrence of step 415 that occurred during the mostrecent occurrence of step 315. Likewise, when the operations of FIG. 16are performed in the furtherance of step 350, the accuracy determinationmade at step 520 is based upon the information obtained at the mostrecent occurrence of step 515 and the information obtained at the mostrecent occurrence of step 415 that occurred during the most recentoccurrence of step 320. Likewise, when the operations of FIG. 16 areperformed in the furtherance of step 355, the accuracy determinationmade at step 520 is based upon the information obtained at the mostrecent occurrence of step 515 and the information obtained at the mostrecent occurrence of step 415 that occurred during the most recentoccurrence of step 325. Likewise, when the operations of FIG. 16 areperformed in the furtherance of step 360, the accuracy determinationmade at step 520 is based upon the information obtained at the mostrecent occurrence of step 515 and the information obtained at the mostrecent occurrence of step 415 that occurred during the most recentoccurrence of step 330. Likewise, when the operations of FIG. 16 areperformed in the furtherance of step 375, the accuracy determinationmade at step 520 is based upon the information obtained at the mostrecent occurrence of step 515 and the information obtained at the mostrecent occurrence of step 415 that occurred during the most recentoccurrence of step 365. Likewise, when the operations of FIG. 16 areperformed in the furtherance of step 380, the accuracy determinationmade at step 520 is based upon the information obtained at the mostrecent occurrence of step 515 and the information obtained at the mostrecent occurrence of step 415 that occurred during the most recentoccurrence of step 370.

More specifically, in accordance with the first embodiment of thepresent invention, the accuracy determination is made at step 520 bydetermining the percentage difference between the data obtained at themost recent occurrence of step 515 and the corresponding data in theinitial database 150.

At step 525 a determination is made as to whether the accuracydetermined at step 520 is sufficient. In accordance with one example,the accuracy determined at step 520 is sufficient if it is plus or minusten percent, although in accordance with other examples greater andlesser accuracy can be acceptable. If a negative determination is madeat step 525, control is transferred to step 530, where the system ofMDME is adjusted appropriately in an effort to increase its accuracy.The system of MDME is not adjusted to compensate for errors associatedwith the manufacturing machine 20, but the system of MDME 13 isinitially adjusted so that the data collected by the system of MDMEclosely conforms to the corresponding data collected by the system ofMEKA. If a positive determination is made at step 525, control istransferred to step 540, and the respective location of the BenchmarkDatabase 140 is populated with the data obtained at the most recentperformance of step 515.

At step 545 the clamp releases the designated component of the system ofMDME. More specifically, at steps 510 and 545 the clamp optionallyrespectively picks up and releases the designated component of thesystem of MDME because when subsequent ones of steps 335, 340, 345, 350,355, 360, 375, and 380 (FIG. 14) utilize the same designated componentof the system of MDME it is preferred that appropriate ones of steps 510and 545 be omitted to avoid having to pick up a designated componentimmediately after releasing the same designated component.

The operations illustrated by FIGS. 17A-B will now be described, inaccordance with the first embodiment of the present invention. Theoperations illustrated by and described with reference to FIGS. 17A-Bare performed in the furtherance of step 390 of FIG. 14B. At step 610 adetermination is made as to whether data for the Performance Database142 is to be obtained with the system of MDME. This determination can bemade in a variety of different ways. As one example, the certifyingsystem can be set up so that data for the Performance Database 142 isobtained with the system of MDME at periodic time intervals.

Referring to FIG. 9, in accordance with the first embodiment of thepresent invention the Performance Database 142 can be characterized asincluding multiple data packages that play a role in the determinationmade at step 610. More specifically, a first data package includes theFirst Axis Data Set, the First Ring Data Set, and the First Cube DataSet (i.e., the first row of the Performance Database 142); a second datapackage includes the Second Axis Data Set, the Second Ring Data Set, andthe Second Cube Data Set (i.e., the second row of the PerformanceDatabase); a . . . data package includes the . . . Axis Data Set, the .. . Ring Data Set, and the . . . Cube Data Set (i.e., the . . . row ofthe Performance Database); and an Nth data package includes the Nth AxisData Set, the Nth Ring Data Set, and the Nth Cube Data Set (i.e., theNth row of the Performance Database). The operations associated withstep 610 are preferably performed so that the data packages are filledsequentially and so that each piece of the data that is used for thefilling is obtained at no more frequently than a predetermined timeinterval. The predetermined time interval can be a certain number ofminutes or hours, or the like, that the manufacturing machine 20 is inoperation. For example, it is preferred for the operations resultingfrom steps 610-650 to take only a little, if any, time away from theproduction time of the manufacturing machine 20. In accordance with oneparticular example, it is preferred for the operations resulting fromsteps 610-650 to consume only approximately one percent of themanufacturing machine's production time on a daily basis. Of course thepredetermined time interval is preferably small enough so that anyproblems with the manufacturing machine 20 do not go undetected for toolong. If a negative determination is made at step 610, control istransferred to step 655. If a positive determination is made at step610, control is transferred to step 615.

At step 615 a determination is made as to which data for the PerformanceDatabase is to be obtained. In accordance with the first embodiment,each of the sequentially filled data packages of the PerformanceDatabase is completely filled before data is collected for subsequentdata packages. Therefore, at step 615 a query is performed to determineif there is a data package that is in the process of being filled. Ifso, then data for that partially filled data package will be obtained.If not, then data for the subsequent data package will be obtained. Oncethe data package for which data is to be obtained is identified, thenthe data that is to be obtained for that data package is selected. Forexample, the data to be obtained will not be duplicative to data alreadyobtained for the subject data package and can be selected through theuse of some type of conventional random selection routine.

At step 620 the clamp 54 or 58 that is used to obtain the dataidentified at the most recent occurrence of step 615 picks up thegrippable component of the system of MDME that is used to obtain thedata identified at the most recent occurrence of step 615 (i.e., theclamp picks up one of the sensor assemblies 102, 130). The clamp 54 or58 that is used to obtain the data identified at the most recentoccurrence of step 615 is referred to herein as the selected clamp. Thegrippable component of the system of MDME that is used to obtain thedata identified at the most recent occurrence of step 615 is referred toherein as the selected component. The data identified at the most recentoccurrence of step 615 is referred to herein as the selected data.

At step 625 the manufacturing machine 20 is operated so that theselected clamp moves the selected component in the manner that isrequired to obtain the selected data. The movement of the selectedcomponent by the selected clamp in the manner that is required to obtainthe selected data is referred to herein as the selected movement. Inaddition, at step 625 the system of MDME obtains the selected data, andthat data is appropriately recorded in the Performance Database.

Examples of the selected movements carried out at subsequent operationsof step 625 will now be described. The selected movements carried out atsubsequent operations of step 625 at least simulate and are preferablyidentical to the operations of step 515 carried out respectively atsteps 335, 340, 345, 350, 355, 360, 375, and 380 (FIG. 14), which aredescribed above. The selected movements carried out at subsequentoperations of step 625 also include moving the touch probe 132 of themechanical sensor assembly 130 into contact with each of the X-Y, upperX-Z, lower X-Z, right Y-Z, and left Y-Z surfaces 120, 122, 124, 126 and128 of the cube target via respective movement of both the upper andlower clamps 54, 58.

At step 630 a determination is made as to whether the manufacturingmachine 20 is operating within tolerances. More specifically, wherepossible the determination is made as to whether the data obtained atthe immediately preceding step 625 is within tolerances with respect tocorresponding data in the Benchmark Database 150. For example, it may berequired that all data obtained for the Performance Database 142 bewithin plus or minus one percent of the corresponding data in theBenchmark Database 140. Or, if corresponding data is not included in theBenchmark Database 140, it may be required that the determination atstep 630 be based on predetermined expectations. For example when thetouch probe 132 of the mechanical sensor assembly 130 is brought intocontact with the cube target 118 at step 625, the data obtained at step625 can pertain to which of the sensors 138 was triggered and to whatdegree. As one example, in the scenario of the preceding sentence it canbe deemed at step 630 that the manufacturing machine 20 is withintolerances if only the tip sensor 138 was triggered at step 625 and thattriggering did not exceed a predetermined value. If a negativedetermination is made at step 630, control is transferred to step 700.If a positive determination is made at step 630, control is transferredto step 635.

At step 635 a determination is made as to whether a predeterminedportion of the Performance Database 142 is filled. More specifically, atstep 635 it is determined whether the data placed in the PerformanceDatabase 142 at the most recent occurrence of step 625 resulted in thecompletion of the process of filling one of the data packages of thePerformance Database with data. If a negative determination is made atsteps 635, control is transferred to step 650. If a positivedetermination is made at step 635, control is transferred to step 640.

At step 640 the entire Performance Database 142 is analyzed in view ofthe Benchmark Database 140. The analysis performed at step 640 canresult in the resetting of tolerances that are used in thedeterminations made at steps 630 and 645, or the like. At step 645 adetermination is made based on an analysis of the entire PerformanceDatabase 142 in view of the Benchmark Database 140 as to whether themanufacturing machine 20 is operating within tolerances or isanticipated to continue operating within tolerances. For example, atstep 645 trends in the data of the Performance Database 142 may beanalyzed in an effort to determine if the manufacturing machine 20 islikely to begin operating unacceptably in the near future. If it isdetermined that the manufacturing machine 20 is likely to operateunacceptably in the near future a negative determination will be made atstep 645. If a negative determination is made at step 645, control istransferred to step 700. If a positive determination is made at step645, control is transferred to step 650.

At step 650, the selected clamp releases the selected component of thesystem of MDME that was gripped at step 620. More specifically, thatselected component of the system of MDME is returned to the tool rack 32at step 650.

At steps 655, 660, 665, and 670 the manufacturing machine 20 operates ina conventional manner to manufacture a part from a workpiece 28, asshould be understood by those of ordinary skill in the art. Morespecifically and for example, at step 655 a workpiece 28 is introducedto and secured to the manufacturing machine 20 via operation of themagnets 30 so that the workpiece is prepared for being machined by themanufacturing machine. At step 660 the clamp 54 or 58 picks up a tool36, and at step 665 the clamp moves the tool so that a part is formedfrom the workpiece introduced to the manufacturing machine at step 655.At step 670 the clamp releases the tool 36 gripped at step 660, and morespecifically that tool is returned to the tool rack 32. Of course steps660, 665, and 670 may be repeated numerous times for both of the clamps54, 58 to facilitate the forming of a part from the workpiece 28, asshould be understood by those of ordinary skill in the art.

At step 675 the clamp 54 or 58 picks up the mechanical sensor assembly130 from the tool rack 32. At step 680 the part/workpiece 28 that wasmost recently manufactured by the manufacturing machine 20 and is stillheld by the magnets 30 is inspected. More specifically, at step 680 theclamp 54 or 58 moves the touch probe 132 of the mechanical sensorassembly 130 across the part that was manufactured from the workpiece 28during the most recent occurrence of step(s) 665 and that remains heldto the bed 22 by the magnets 30. Step 680 may be reperformed in aloop-like fashion so that both of the clamps 54, 58 are used in theinspection of the part/workpiece 28. Inspection data collected at step680 is placed within a Quality Control Database (not shown), and at step685 that data is compared to expected data to determine if the inspectedpart/workpiece 28 is within predetermined tolerances. More specifically,the inspection data collected at step 680 is illustrative of the actualconfiguration of the manufactured part/workpiece 28, and that actualconfiguration is compared to the desired configuration of the part thatthe manufacturing machine 20 was programmed to provide. If a negativedetermination is made at step 685, control is transferred to step 700.If a positive determination is made at step 685, control is transferredto step 690. In addition, data is preferably added to and accumulated inthe Quality Control Database each time step 680 is performed, and thataccumulated data can be analyzed and trended in a variety of differentmanners to provide meaningful information about, and appropriatewarnings with respect to, the operational characteristics of themanufacturing machine 20.

At step 690 the part/workpiece 28 that has been most recentlymanufactured by and inspected by the manufacturing machine 20 isdischarged from the manufacturing machine, such as by de-energizing themagnets 30. At step 695, which could be performed before step 690, theclamp 54 or 58 releases the mechanical sensor assembly 130, and morespecifically the clamp returns the mechanical sensor assembly to thetool rack 32. Control is transferred from step 695 to step 610.

Control is transferred to step 700 when a negative determination is madeat any of steps 630, 645, or 685. At step 700 the certifying systemfunctions to generate a signal that is indicative of the manufacturingmachine 20 not operating within tolerances, and in accordance with oneexample the signal is operative to shut down the manufacturing machine.

If the manufacturing machine 20 is not operating within tolerances, thePerformance Database 142 and the Benchmark Database 140 can be analyzed,and often from that analysis it will become apparent to maintenancepersonnel which axis or element of the manufacturing machine needs to beadjusted or repaired, as should be understood by those of ordinary skillin the art. For example, corrective actions performed by maintenancepersonnel can include adjustments to mechanical drives, bearings, gibbsand ways, servo motors, positioning feedback devices, and the like.

In accordance with the first embodiment of the present invention, acomputer program product includes a computer-readable storage mediumhaving a software module, which can be characterized ascomputer-readable program code means having a series of computerinstructions that are embodied in the computer-readable storage medium,for facilitating the operations of the method of the present invention,which are discussed above. In this regard, FIGS. 14A-B, 15-16, and 17A-Bcan be characterized as block diagram, flow chart and control flowillustrations of methods, systems and program products according to theinvention. It will be understood that each block or step of the blockdiagram, flow chart and control flow illustrations, and combinations ofblocks in the block diagram, flow chart and control flow illustrations,can be implemented by computer program instructions.

More specifically, in accordance with the first embodiment of thepresent invention, all of the operations described above, except forthose carried out by a user of the present invention, are preferablyimplemented by computer program instructions. These computer programinstructions may be loaded onto a computer or other programmableapparatus to produce a machine, such that the instructions which executeon the computer or other programmable apparatus create means forimplementing the functions specified in the block diagram, flow chart orcontrol flow block(s) or step(s). These computer program instructionsmay also be stored in a computer-readable memory that can direct acomputer or other programmable apparatus to function in a particularmanner, such that the instructions stored in the computer-readablememory produce an article of manufacture including instruction meanswhich implement the function specified in the block diagram, flow chartor control flow block(s) or step(s). The computer program instructionsmay also be loaded onto a computer or other programmable apparatus tocause a series of operational steps to be performed on the computer orother programmable apparatus to produce a computer implemented processsuch that the instructions which execute on the computer or otherprogrammable apparatus provide steps for implementing the functionsspecified in the block diagram, flow chart or control flow block(s) orstep(s).

Accordingly, blocks or steps of the block diagram, flow chart or controlflow illustrations support combinations of means for performing thespecified functions, combinations of steps for performing the specifiedfunctions and program instruction means for performing the specifiedfunctions. It will also be understood that each block or step of theblock diagram, flow chart or control flow illustrations, andcombinations of blocks or steps in the block diagram, flow chart orcontrol flow illustrations, can be implemented by special purposehardware-based computer systems which perform the specified functions orsteps, or combinations of special purpose hardware and computerinstructions.

Those skilled in the art will appreciate that there are many differentconventional programming languages that are available and that can bereadily used to create the software module of the present invention.Acceptable programming languages are the Valisys and Caps & Edges brandprogramming languages. The software module of the present inventionpreferably operates in conjunction with a conventional computer system,an acceptable example of which is diagrammatically illustrated in FIG.3. The software module of the present invention preferably provides agraphical user interface via the display 72, and the graphical userinterface includes multiple display screens that are presented to a userof the software module via the display. The display screens displayinformation that a user has input or selected, and information that thesoftware module outputs. A user may input information in a conventionalmanner via the input device 70.

Second Embodiment

A second embodiment of the present invention is identical to the firstembodiment, except for variations that are noted and variations thatwill be apparent to those of ordinary skill in the art. Referring toFIG. 18, in accordance with the second embodiment, cube targets 118′ areused in place of the cube targets 118 (FIGS. 2 and 7) of the firstembodiment, and the cube targets 118′ of the second embodiment areconstructed and arranged so that in accordance with the secondembodiment the ring targets 112, 114 (FIGS. 2 and 6) of the firstembodiment are not required.

Referring to FIG. 18, the representative cube target 118′ can includemultiple pocket-like annular ring targets that are respectively definedin and parallel to each of the accessible surfaces (i.e., the X-Ysurface, the upper and lower X-Z surfaces, and the right and left Y-Zsurfaces) of the cube target 118′. For example, three separatepocket-like annular ring targets 154 are seen in FIG. 18, and they arerespectively defined in the X-Y surface 120′, the upper X-Z surface122′, and the right Y-Z surface 126′. In accordance with the secondembodiment, the steps that were described as being carried out withrespect to the ring targets 112, 114 (FIGS. 2 and 6) of the firstembodiment are carried out with respect to each of the pocket-likeannular ring targets 154. For example and in accordance with the secondembodiment, ball-bar emulation is performed around the three pocket-likeannular ring targets 154 illustrated in FIG. 18.

Many modifications and other embodiments of the invention will come tomind to one skilled in the art to which this invention pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that theinvention is not to be limited to the specific embodiments disclosed andthat modifications and other embodiments are intended to be includedwithin the scope of the appended claims. Although specific terms areemployed herein, they are used in a generic and descriptive sense onlyand not for purposes of limitation.

What is claimed is:
 1. A method of operating a machine that is capableof machining a workpiece by establishing relative movement between atool and the workpiece, the method comprising: performing a firstoperation of the machine; obtaining first data by quantifying the firstoperation of the machine using first measurement equipment of knownaccuracy; performing a second operation of the machine; obtaining seconddata by quantifying the second operation of the machine using secondmeasurement equipment; determining the accuracy of the secondmeasurement equipment by quantifying at least one difference between thefirst and second data; machining a workpiece with the machine afterdetermining the accuracy of the second measurement equipment; performinga third operation of the machine after machining the workpiece; andobtaining third data by quantifying the third operation of the machineusing the second measurement equipment.
 2. A method according to claim1, further comprising: quantifying the difference between the second andthird data; and generating a signal in response to the differencebetween the second and third data exceeding a predetermined value.
 3. Amethod according to claim 1, wherein the step of performing the thirdoperation comprises: operating the machine to inspect the workpieceafter the workpiece has been machined by the machine.
 4. A methodaccording to claim 1, wherein: the step of performing the firstoperation comprises operating the machine to cause a clamp of themachine to travel along a path; and the step of obtaining first datacomprises using the first measurement equipment to determine howaccurately the clamp traveled along the path.
 5. A method according toclaim 4, wherein: the step of operating the machine to cause the clampof the machine to travel along the path comprises operating the machineto cause the clamp of the machine to travel along a curved path; and thestep of using the first measurement equipment to determine howaccurately the clamp traveled along the path comprises using the firstmeasurement equipment to determine how accurately the clamp traveledalong the curved path.
 6. A method according to claim 4, wherein: thestep of operating the machine to cause the clamp of the machine totravel along the path comprises operating the machine to cause the clampof the machine to travel along a straight path; and the step of usingthe first measurement equipment to determine how accurately the clamptraveled along the path comprises using the first measurement equipmentto determine how accurately the clamp traveled along the straight path.7. A method according to claim 1, wherein: the step of performing thesecond operation comprises operating the machine to cause the clamp ofthe machine to travel along a path; and the step of obtaining seconddata comprises using the second measurement equipment to determine howaccurately the clamp traveled along the path.
 8. A method according toclaim 7, wherein: the step of operating the machine to cause the clampof the machine to travel along the path comprises operating the machineto cause the clamp of the machine to travel along a curved path; and thestep of using the second measurement equipment to determine howaccurately the clamp traveled along the path comprises using the secondmeasurement equipment to determine how accurately the clamp traveledalong the curved path.
 9. A method according to claim 7, wherein: thestep of operating the machine to cause the clamp of the machine totravel along the path comprises operating the machine to cause the clampof the machine to travel along a straight path; and the step of usingthe second measurement equipment to determine how accurately the clamptraveled along the path comprises using the second measurement equipmentto determine how accurately the clamp traveled along the straight path.10. A method according to claim 1, wherein: the step of performing thethird operation comprises operating the machine to cause the clamp ofthe machine to travel along a path; and the step of obtaining third datacomprises using the second measurement equipment to determine howaccurately the clamp traveled along the path.
 11. A method according toclaim 10, wherein: the step of operating the machine to cause the clampof the machine to travel along the path comprises operating the machineto cause the clamp of the machine to travel along a curved path; and thestep of using the second measurement equipment to determine howaccurately the clamp traveled along the path comprises using the secondmeasurement equipment to determine how accurately the clamp traveledalong the curved path.
 12. A method according to claim 10, wherein: thestep of operating the machine to cause the clamp of the machine totravel along the path comprises operating the machine to cause the clampof the machine to travel along a straight path; and the step of usingthe second measurement equipment to determine how accurately the clamptraveled along the path comprises using the second measurement equipmentto determine how accurately the clamp traveled along the straight path.